Using concrete forming systems to build pools

by jason_cramp | March 7, 2021 2:56 pm

By Frank Wall

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With the massive demand for new pool construction, some builders are re-evaluating the way in which they install their pools. Last season, because of the COVID-19 pandemic, pool kit manufacturers were locked down for several weeks, which resulted in lost production time for builders right at the beginning of the pool season as material delays were inevitable. As a result, there is renewed interest in aluminum forming systems as builders look for alternative solutions that give them more options when it comes to building pool walls. In fact, many are investing in their own aluminum forming systems that allow them to build concrete wall vinyl-liner pools in virtually any shape and on their own schedule.

Standing out from competitors

Even before the pandemic, reusable concrete forms were growing in popularity because they enable builders to create unique shapes and features and, in turn, help them stand out from their competitors. The ability for builders to offer their clients a custom pool design allows them to compete on more than just price. In fact, last year many installers looked to using aluminum forms to build concrete walls for their unique vinyl-liner pool designs.

Vinyl-liner pools built with concrete walls can now support designs that include many features that, in the past, were typically associated only with custom gunite or shotcrete structures.

Randy Budd of Budd’s Pools in Deptford, N.J., started using reusable aluminum concrete forms several years ago when building his vinyl-liner
pool projects.

“The concrete walls enable me to differentiate myself. When consumers come into my shop, they see we are offering pools very different from those offered by our competition,” he says.

Budd also notes homeowners are drawn to the structural strength of concrete, but appreciate the serviceability and affordability of liners. That said, his company now builds vinyl-liner pools with poured concrete walls and, recently, has moved into building all-concrete pools.

“It’s still primarily about differentiation for our company, but we also highly value our ability to have more control over our building schedule—especially this past season,” says Budd.

Using reusable aluminum forms

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Vinyl-liner pools built with poured concrete walls have a long history of success in the northeast and southeast areas of the U.S. and are now becoming more popular in Canada. Initially, the forms were built from steel, wood, or fibreglass, but these were costly, hard to maintain, and heavy. In contrast, today’s aluminum forming systems are not only lighter and easier to maintain, but also come in a variety of shapes and sizes, which allows builders to create geometric and freeform shapes, a number of different pool step styles (e.g. in-pool, corner, full end [often called stadium steps]), benches, tanning ledges, raised walls, attached spillover spas, vanishing edges, automatic cover boxes, and beach entries. Builders can place every feature at once during one pour.

In addition to using a forming system to build vinyl-lined pools, they can also be used to construct all-concrete pools. They can even be stacked to create raised walls for water features and raised deck areas around the pool. They are quite versatile as builders can even use them to pour retaining walls, as well as basement or other type of support wall.

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Aluminum forming systems comprise an inside and outside panel form held together by wall ties that are inspected to yield a minimum pull strength of 3175 kg (7000 lbs). The ties are also notched for easy rebar placement. The forms fit together fast and easy using a pin-and-wedge system. These features keep labour costs to a minimum during the setting and stripping stages. Once the forms, plumbing, and structural steel are in place, a special design mix of 27,579 kPa (4000 psi) concrete with specified chemical add mixtures that produces stronger, faster setting and easier workable and flowable mix is used to create a 254-mm (10-in.) thick wall.

Typically, aluminum forming systems are 1219 mm (48 in.) in height and, when using the wall’s depth-pouring gauges, builders can pour either a 1067-mm (42-in.) or 1219-mm (48-in.) wall. The system does not require any footings and is set up directly on the ground. Before pouring concrete into the aluminum forms, a very light coat of release agent needs to be sprayed onto the surface. After allowing the concrete to cure for 12 hours, the forms are stripped, leaving builders with 254-mm (10-in.) thick reinforced pool walls. The walls are then finished just like any other pool wall system along with the vermiculite or concrete-grout floor.

After the forms are stripped, they can be cleaned and readied for the next project.

Once a builder buys a set of aluminum forms, they become the manufacturer of their pools and are no longer dependent on other material suppliers to determine when they can start building their projects. Additionally, builders can also eliminate any material shipment delays and paying expensive freight costs. In fact, the cost of a concrete aluminum forming system becomes less expensive after every pool installation. Further, with proper care, a forming system can last well over 3500 pours.

Comparing costs

When comparing the price of using an aluminum forming system versus a traditional vinyl-liner pool kit system, many builders see savings because of the efficiency of the construction process as every part of the pool is made of concrete.

“If the excavation goes well, the project will go well,” says Greg Butler, the owner of Bubba’s Pools & Tubs in Mount Pearl, Nfld., who has been using aluminum forms to construct pool projects for more than six years. “Concrete is reliable and readily available, and the savings is not only a result of the reliability, but also the simplicity.”

According to Butler, his company’s cost per pool installation are lower because he does not have to worry about lost income due to shipping delays, missing pieces, or damaged freight (e.g. dented steel panels).

“We no longer do crazy things like go to a local steel shop to get a panel repaired,” says Butler. “We are in a fairly isolated market and any delay on a pool project really used to disrupt our building schedule, which is extremely short in Newfoundland.”

Budd adds his company’s per-pool profit has increased since they started building concrete wall vinyl-lined pools.

“The reason is two-fold,” says Budd. “We are able to charge more for our unique designs and our freight and labour costs are also lower per pool.”

Additional benefits

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In addition to higher-per-pool profits and greater control of the construction schedule, when using these forming systems, pool builders can present their clients with a variety of creative options for their pool.

“Using an aluminum forming system has allowed us to quickly and comfortably move from standard shapes into more creative designs,” says Budd.

In most cases, in the first year of building concrete wall pools with these forms, some builders will stay within the standard shapes and drawings they are accustomed to using. That said, by the second or third season, most builders realize how creative they can really get. This creativity has led builders to use the forms to install retaining walls and other masonry structures beyond the water’s edge and moving toward a number of other projects that encompass the surrounding landscape, too.

“If you see the liner pools we’re building now, it’s difficult to tell it’s a vinyl pool,” says Budd. “Probably three quarters of the people who look at them simply assume it’s a gunite pool.”

There is also the positive perception from the client that concrete walls are strong and solid.

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“During the construction process, when the forms are stripped and the homeowner sees they have something substantial in their backyard that is big and robust, they realize they have something very solid and strong and are always happy with the way it looks.

“This is a benefit a pool installer can’t always measure, but yet, provides a perception of quality and strength that furthers a builder’s positive reputation.”

As a result of the increased demand for pools during the pandemic, many builders are either incorporating or using aluminum forming systems in their projects to pour concrete walls. Although having more control over one’s installation schedule might be the main reason for builders to invest in a set of aluminum forms, the lower cost per pool and the ability to create unique designs, as well as offer other landscaping structures, make this construction tool an attractive investment.

[6]Frank Wall built vinyl-liner and gunite pools for more than 30 years at Modern Pool Systems in Mississippi. In 2007, he closed his construction business and concentrated on developing products for the construction industry that are not normally found in building supply houses. Among these products was AquaForms—an aluminum concrete forming system designed for pool builders. Wall can be reached via email at frank@frankwall.com[7].

Source URL: https://www.poolspamarketing.com/trade/using-concrete-forming-systems-to-build-pools/

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